Cutting/polishing tool and manufacturing method thereof

ABSTRACT

There are provided a cutting/polishing tool that may be readily manufactured and have an improved cutting performance, and a manufacturing method thereof. The method for manufacturing the cutting/polishing tool including at least one cutting/polishing body may comprise preparing a tool body, and forming a cladding layer including cutting material particles by spraying, onto an outer surface of the tool body, the cutting material particles and a metal powder having a specific gravity greater than a specific gravity of the cutting material particles while heating the outer surface of the tool body using a heating device installed in a lower side of the outer surface of the tool body so that the metal powder is deposited on the outer surface of the tool body, wherein the cladding layer configures the at least one cutting/polishing body.

TECHNICAL FIELD

The present invention relates to a cutting/polishing tool used forcutting, boring, or polishing a workpiece of a material such as a metal,a ceramic, a semiconductor, stone, brick, concrete, asphalt, and thelike, and a manufacturing method thereof, and more particularly, to acutting/polishing tool that is easily manufactured, and a manufacturingmethod thereof.

BACKGROUND ART

In general, to perform a cutting operation or a polishing operation,particles having excellent abrasion resistance such as diamondparticles, carbide, boric acids, nitrides, hard metal and ceramic piecesmay be used. Among these, diamonds are well-known as being the hardestsubstances on Earth, and have been widely used for a cutting tool or agrinding (polishing) tool due to this fact.

Typically, a diamond tool configured as segments may include acutting/polishing segment (cutting tip) on which the diamond particlesare distributed, and a metal body (tool body or shank) to which thecutting/polishing segment is fixed.

FIG. 1 is a view showing examples of various types of diamond toolsconfigured as segments. As shown in FIG. 1 (a), a saw blade 10 aconfigured as segments includes a plurality of segments 12 a (cuttingtips) that are fixed to a disk shaped-metal body 11 a. A core bit 10 bconfigured as segments, as shown in FIG. 1(b), includes a plurality ofsegments 12 b (cutting tips) that are fixed to a metal body 11 b, and apolishing wheel 10 c configured as segments, as shown in FIG. 1(c),includes a plurality of segments 12 c (polishing tips) that are fixed toa bottom surface of a metal body 11 c. As for the above describedsegments 12 a, 12 b, and 12 c of the cutting/polishing tools 10 a, 10 b,and 10 c, diamond particles (D) are randomly distributed between metalpowders (bond metal) (M), and the diamond particles distributed in eachsegment may perform a cutting/polishing operation.

To manufacture the above described cutting/polishing segment, a powdermetallurgy scheme may be generally used. Specifically, metal powder anddiamond particles (crystals) are mixed, and the mixture is molded into acutting/polishing segment shaped-form. Then, the obtained molding isheated to a high temperature to form the cutting/polishing segment withdense tissue through a sintering scheme or a hot pressing scheme.Thereafter, the cutting/polishing segment is bonded to the tool body(shank), and in this bonding process, a laser welding, a brazing using asilver solder, a diffusion bonding using sintering, and the like may beused. However, the above described tool manufacturing method may havemany problems in that a complex process such as sintering and the likemay be required for manufacturing the cutting/polishing segment, and anadditional process such as a welding operation, or the like, may berequired for fixing the cutting/polishing segment to the tool body, andtherefore many processes and facilities may be required formanufacturing the cutting/polishing tool, and much labor may be alsorequired.

In order to overcome these problems, there is disclosed Korean PatentNo. 452563 (U.S. Pat. No. 6,316,065) directed to a manufacturing methodfor a cutting tool using a laser cladding technology.

As shown in FIG. 2(a), in a manufacturing method for a cutting tooldisclosed in Korean Patent No. 452563, a mixed powder of the metalpowder (M) and the diamond particles (D) may be sprayed using a powdersupplying device 30 while heating an outer surface 11 a of a tool body11 using a laser heating device 20, and the mixed powder of the metalpowder (M) and the diamond particles (D) may be deposited on the outersurface 11 a of the tool body 11 to form a cutting body 12. In thisinstance, while the cutting body 12 is formed on the tool body 11 of thecutting tool, the tool body 11 may be moved to a direction (X) oppositeto a gravity direction (G), and an angle (±w) between the gravitydirection (G) and a line perpendicular to a section (S) where thedeposition is performed by a laser heating device 20 may be maintainedin a range of 60 degrees to 90 degrees for a time period during whichthe mixed powder is clotted. Also, as shown in FIG. 4, even in a case offorming a cutting body 12′ on an outer surface 11 a′ while rotating adisk-shaped tool body 11′, the angle (±w) between the gravity direction(G) and the line perpendicular to the section (S) where the depositionis performed may be maintained in the range of 60 degrees to 90 degreesfor the time period during which the mixed powder is clotted.

As described above, the manufacturing method for the cutting tool shownin FIG. 2(a) and FIG. 4 may allow the cutting tool to be manufacturedthrough a single process by laser-cladding the metal powder (M) and thediamond particles (D) directly onto the tool bodies 11 and 11′, andthereby may improve productivity and reduce manufacturing costs. Also,in the case of sintering the cutting/polishing segment, a mechanicalbond between the diamond particles and the metal powder is achieved,however, in a case of using the laser cladding technology, a chemicalbond between the diamond particles and the metal powder is achieved andthus, the manufacturing method may improve an adhesion and a quality ofthe tool thereby.

In addition, as for the manufacturing method for the cutting tooldisclosed in the above Korean Patent, since the tool body 11 may bemoved in the direction (X) opposite to the gravity direction (G) whilebeing heated in a practically horizontal direction using the laserheating device 20, there is an advantage in that a distribution range ofthe diamond particles (D) is relatively widened in comparison with therelated art (background art of the Korean Patent No. 452563) where heatis applied from an upper side of the tool body 11.

Meanwhile, in the case of manufacturing the cutting tool using the lasercladding process, a melting and a clotting momentarily occur in an areawhere a laser beam is radiated, however, the diamond particles may bemoved in the direction opposite to the gravity direction, due to aspecific gravity difference between the diamond particles and a meltedmetal powder, even in the short period of time.

Specifically, referring to FIG. 2(b), an oval shaped-molten pool may begenerated on a processing part of the cutting body 12 corresponding to asection (S) where the laser beam is radiated, by a transfer speed of thetool body 11 and a radiation direction of the laser beam, and thediamond particles (D) may be momentarily moved to a top end of themolten pool due to a specific gravity lower than a specific gravity ofthe molten metal powder (M). Specifically, the diamond particles (D) maybe densely located in a part of the oval-shaped molten pool that is farfrom the outer surface 11 a of the tool body 11.

Consequently, in the manufacturing method for the cutting tool disclosedin the Korean Patent, since the diamond particles (D) are denselylocated only in an outer surface side of the cutting body 12 as shown inFIG. 3, the diamond particles (D) are not uniformly distributedthroughout the entire cutting body 12 and thus, the efficiency of thecutting tool may not be uniformly achieved, and the cutting body 12 maynot be used as a whole.

Also, in the manufacturing method for the cutting tool disclosed in theKorean Patent, there is a problem in that since the diamond particles(D) are densely located on the outer surface side of the cutting body12, that is, the outer surface, an additional laser cladding process maynot be performed in a part of the previously formed cutting body 12.That is, in a case of melting the outer surface of the previously formedcutting body 12 by repeatedly applying heat to the outer surface of thepreviously formed cutting body 12, the cutting performance of thediamond particles may be degraded and oxidation of the diamond particlesmay be easily generated due to properties of the diamond particles thatare susceptible to heat. In addition, since the metal powder (M)restraining the diamond particles (D) may be re-melted, restraints onthe diamond particles (D) may be released, so that the deposited diamondparticles may be floating so as to be densely located in the outersurface side of the molten pool. As a result, it is difficult to performlaser cladding processes multiple times.

DISCLOSURE Technical Problem

An aspect of the present invention provides a cutting/polishing toolthat may be readily manufactured, and have an improved cuttingperformance due to a uniform distribution of cutting material particles,and a manufacturing method thereof.

Another aspect of the present invention provides a cutting/polishingtool that may perform a laser cladding process a plurality of times toincrease a thickness of a cutting/polishing body, and a manufacturingmethod thereof.

Another aspect of the present invention provides a cutting/polishingtool that may obtain a cutting/polishing body having a widened areathrough a cladding process performed a plurality of times, and amanufacturing method thereof.

Yet another aspect of the present invention provides a cutting/polishingtool that may adjust an amount of cutting material particles included ina cladding layer, or control a thickness (height) of the cladding layer,and a manufacturing method thereof.

Another aspect of the present invention provides a cutting/polishingtool that may control a temperature of a molten pool to prevent aperformance of cutting material particles from being degraded, and amanufacturing method thereof.

Further aspect of the present invention provides a method formanufacturing a cutting/polishing tool that may repair a damagedcutting/polishing tool.

Further aspect of the present invention provides a cutting/polishingtool that may divide a single cladding layer a plurality of times tohave a complex-shaped cutting/polishing body, and a manufacturing methodthereof.

Technical Solution

According to an aspect of the present invention, there is provided amethod for manufacturing a cutting/polishing tool including at least onecutting/polishing body, the method including: preparing a tool body; andforming a cladding layer including cutting material particles byspraying, to an outer surface of the tool body, the cutting materialparticles and a metal powder having a specific gravity greater than aspecific gravity of the cutting material particles while heating theouter surface of the tool body using a heating device installed in alower side of the outer surface of the tool body so that the metalpowder is deposited on the outer surface of the tool body and thecutting material particles are distributed in the cladding layer,wherein the cladding layer configures the at least one cutting/polishingbody.

The method may further include accumulating at least one new claddinglayer including the cutting material particles by spraying, to an outersurface of the previously formed cladding layer, the cutting materialparticles and the metal powder while heating the outer surface of thepreviously formed cladding layer using the heating device so that themetal powder is deposited on the outer surface of the previously formedcladding layer, wherein the accumulated cladding layer configures thecutting/polishing body.

According to another aspect of the present invention, there is provideda method for manufacturing a cutting/polishing tool including at leastone cutting/polishing body, the method including: preparing a tool body;forming a cladding layer including cutting material particles byspraying, to an outer surface of the tool body, the cutting materialparticles and a metal powder while heating the outer surface of the toolbody using a heating device so that the metal powder is deposited on theouter surface of the tool body and the cutting material particles aredistributed in the cladding layer and accumulating at least one newcladding layer including the cutting material particles by spraying, toan outer surface of the previously formed cladding layer, the cuttingmaterial particles and the metal powder while heating the outer surfaceof the previously formed cladding layer using the heating device so thatthe metal powder is deposited on the outer surface of the previouslyformed cladding layer and the cutting material particles are distributedin the new cladding layer, wherein the accumulated cladding layerconfigures the cutting/polishing body.

The outer surface of the tool body may be divided into a plurality ofcladding layer-forming sections corresponding to a part where thedeposition of the metal powder is processed by the heating device inaccordance with a relative transfer of the tool body and the heatingdevice, and an angle between a vertical line perpendicular to thecladding layer-forming section and a gravity direction may be in a rangeof −10 degrees to 40 degrees.

The cladding layer-forming section of the tool body may be moved to adirection perpendicular to a gravity direction, and an angle between avertical line perpendicular to the cladding layer-forming section andthe gravity direction may be maintained in a range of −10 degrees to 40degrees during a process where the cutting material particles arefloating within the cladding layer-forming section to be fixedlylocated.

The heating device may heat the cladding layer-forming section whileforming an angle smaller than 40 degrees with respect to a gravitydirection.

Meanwhile, to form the cladding layer having a wide area (range), thecladding layer may be formed such that a plurality of segment layersincluding the cutting material particles are combined while the metalpowder is deposited. In this case, the cladding layer may be formed suchthat the plurality of segment layers, classified depending on whether toinclude the cutting material particles and a content of the cuttingmaterial particles, is combined. As an example, the cladding layer mayinclude a first segment layer including the cutting material particleswhile the metal powder is deposited, and a second segment layer notincluding the cutting material particles while the metal powder isdeposited.

Also, the forming of the cladding layer may be performed while adjustinga spraying amount of at least one of the cutting material particles andthe metal powder so that a height of the cladding layer is adjusted.

In addition, during the forming of the cladding layer, a single claddinglayer may be formed by forming the plurality of segment layers, and theaccumulating may form the plurality of segment layers, where the metalpowder is deposited on the outer surface of the cladding layer formedsuch that the plurality of segment layers are combined, to thereby formthe accumulated cladding layer and thus, a cutting/polishing body havinga wide area and a great thickness may be formed.

Meanwhile, the forming of the cladding layer may determine an amount ofeach of the cutting material particles and the metal powder so that thecutting material particles are not exposed to the outside after thedeposition of the metal powder is completed. On the other hand, theaccumulating may determine an amount of each of the cutting materialparticles and the metal powder so that the cutting material particlesare not exposed to the outside after the deposition of the metal powderis completed.

In addition, the method may further include, after the accumulating,dressing the cutting/polishing body and exposing the cutting materialparticles to the outside.

The forming of the cladding layer may determine an amount of each of thecutting material particles and the metal powder so that a part of thecutting material particles is exposed after the deposition of the metalpowder is completed, and the cladding layer formed as a single layerthrough the forming of the cladding layer may configure thecutting/polishing body.

Also, the forming of the cladding layer and/or the accumulating may beperformed by performing a translational movement, a rotary movement, ora translational/rotary movement with respect to the tool body.

Meanwhile, the heating device may be a laser device. In this instance,when including diamond particles as the cutting material particles, theheating device may be a laser device emitting a laser having awavelength that penetrates through the diamond particles. The laserdevice may be any one of a CO₂ laser device, an Nd-YAG laser device, afiber laser device, a diode laser device, and a disk laser device. Also,since the diamond particles are susceptible to heat, an output of theheating device may be adjusted such that a temperature of a molten poolin which the metal powder is melted does not exceed a presettemperature.

In addition, a spraying amount of each of the cutting material particlesand the metal powder may be separately controlled.

Meanwhile, the method for manufacturing the cutting/polishing toolaccording to an aspect of the present invention may be applied to repaira tool including a damaged cutting/polishing body, and in this case, theforming of the cladding layer may be performed with respect to thedamaged cutting/polishing body.

According to still another aspect of the present invention, there isprovided a cutting/polishing tool, including: a tool body; and at leastone cutting/polishing body including a cladding layer having cuttingmaterial particles while the cladding layer is formed such that a metalpowder is deposited on an outer surface of the tool body, wherein thecutting material particles of the cladding layer are more denselylocated in a part closer to the tool body rather than a part furtheraway from the tool body. Here, the cladding layer may be directly formedon the outer surface of the tool body. In this instance, thecutting/polishing body may be formed such that a plurality of claddinglayers are accumulated, and the cutting/polishing body may include thecutting material particles having a uniform distribution throughout athickness of the cutting/polishing body.

Also, the cladding layer may be formed such that a plurality of segmentlayers are combined. Here, the plurality of segment layers may be formedsuch that the metal powder is deposited.

In addition, the cladding layer may be formed such that a plurality ofsegment layers are combined. Here, the plurality of segment layers maybe classified depending on whether to include the cutting materialparticles and a content of the cutting material particles. In this case,as an example, the cladding layer may comprise a first segment layerincluding the cutting material particles while the metal powder isdeposited, and a second segment layer not including the cutting materialparticles while the metal powder is deposited.

Also, in a case where a single cladding layer configures thecutting/polishing body, the cladding layer may have a configurationwhere a portion of the cutting material particles is exposed to theoutside without being covered with the metal powder.

Advantageous Effects

As set forth above, according to exemplary embodiments of the presentinvention, it is possible to directly form a cutting/polishing body on atool body using a laser cladding process, thereby readily manufacturingthe cutting/polishing tool.

Further, according to an exemplary embodiment of the present invention,since an outer surface of a tool body may be heated using a heatingdevice installed on a lower side of the tool body and cutting materialparticles are floating upwardly (towards the tool body) within a moltenpool, it is possible to form an additional cladding layer on thepreviously formed cladding layer, and thereby a thickness (height) ofthe cutting/polishing body may be increased.

In addition, according to an exemplary embodiment of the presentinvention, it is possible to manufacture the cutting/polishing tool tohave an improved cutting performance due to a uniform distribution ofthe cutting material particles by adjusting an angle range of a gravitydirection and a molten pool section and also adjusting a supply amountof the metal powder and the cutting material particles.

Further, according to an exemplary embodiment of the present invention,it is possible to manufacture the cutting/polishing tool that may havethe cutting/polishing body having a widened area by forming a pluralityof segment layers and forming a single cladding layer using theplurality of segment layers.

Further, according to an exemplary embodiment of the present invention,it is possible to manufacture various types of the cutting/polishingtool by controlling a spraying amount of each of the cutting materialparticles and the metal powder, and thereby may adjust a height(thickness) of the cladding layer.

Further, according to an exemplary embodiment of the present invention,it is possible to control a temperature of a molten pool to prevent aperformance of the cutting material particles from being degraded.

Further, according to an exemplary embodiment of the present invention,it is possible to use the method for manufacturing a cutting/polishingtool of the present invention for repairing a damaged cutting/polishingtool.

Further, according to an exemplary embodiment of the present invention,it is possible to manufacture a cutting/polishing tool that may have acomplex-shaped cutting/polishing body by forming a plurality of segmentlayers, and forming a single cladding layer using the plurality ofsegment layers.

DESCRIPTION OF DRAWINGS

FIG. 1 is a view showing examples of various types of a diamond toolconfigured as segments according to a related art:

(a) is an example of a saw blade configured as segments,

(b) is an example of a core bit configured as segments, and

(c) is an example of a polishing wheel configured as sections.

FIG. 2 is a schematic view showing a prior art method for manufacturinga cutting tool having a plane cutting body according to a related art:

(a) is a partial cross-sectional view showing a process of manufacturinga cutting body by a cladding operation, and

(b) is an enlarged view of “A”.

FIG. 3 is a cross-sectional view taken along a B-B line of FIG. 2(a).

FIG. 4 is a schematic view showing a prior art method for manufacturinga cutting tool having a circular cutting body according to the relatedart.

FIG. 5 is a schematic view showing a method for manufacturing acutting/polishing tool according to an exemplary embodiment of thepresent invention.

FIG. 6 is an enlarged view of a cladding layer-forming section of FIG.5.

FIG. 7 is a schematic view showing a method for manufacturing acutting/polishing tool according to another exemplary embodiment of thepresent invention.

FIG. 8 is a schematic view showing a method for manufacturing acutting/polishing tool having a plane cutting/polishing body accordingto an exemplary embodiment of the present invention.

FIG. 9 is a schematic view showing a method for manufacturing acutting/polishing tool according to another exemplary embodiment of thepresent invention.

FIG. 10(a) is a schematic view sequentially showing a method formanufacturing a cutting/polishing tool including a plurality ofaccumulated cladding layers according to an exemplary embodiment of thepresent invention.

FIG. 10(b) is another schematic view sequentially showing a method formanufacturing a cutting/polishing tool including a plurality ofaccumulated cladding layers according to an exemplary embodiment of thepresent invention.

FIG. 10(c) is yet another schematic view sequentially showing a methodfor manufacturing a cutting/polishing tool including a plurality ofaccumulated cladding layers according to an exemplary embodiment of thepresent invention.

FIG. 11(a) is a partially cut-away perspective view showing an exampleof a cutting/polishing tool having a wide area according to an exemplaryembodiment of the present invention.

FIG. 11(b) is a partially cut-away perspective view showing anotherexample of a cutting/polishing tool having a wide area according to anexemplary embodiment of the present invention.

FIG. 11(c) is a partially cut-away perspective view showing yet anotherexample of a cutting/polishing tool having a wide area according to anexemplary embodiment of the present invention.

FIG. 12 is a partially cut-away perspective view showing acutting/polishing tool in which a plurality of cladding layers having awide area are accumulated according to an exemplary embodiment of thepresent invention.

FIG. 13(a) is a cross-sectional view showing a cutting/polishing toolincluding a cutting/polishing body configured as a single cladding layeraccording to an exemplary embodiment of the present invention.

FIG. 13(b) is a cross-sectional view showing another cutting/polishingtool including a cutting/polishing body configured as a single claddinglayer according to an exemplary embodiment of the present invention.

FIG. 14 is a partially cut-away perspective view showing acutting/polishing tool configured as a single cladding layer and havinga wide area according to an exemplary embodiment of the presentinvention.

FIG. 15(a) is an example of a cutting/polishing tool that ismanufactured into various shapes according to an exemplary embodiment ofthe present invention.

FIG. 15(b) is another example of a cutting/polishing tool that ismanufactured into various shapes according to an exemplary embodiment ofthe present invention.

FIG. 15(c) is yet another example of a cutting/polishing tool that ismanufactured into various shapes according to an exemplary embodiment ofthe present invention.

FIG. 15(d) is still another example of a cutting/polishing tool that ismanufactured into various shapes according to an exemplary embodiment ofthe present invention.

BEST MODE

Hereinafter, exemplary embodiments will be described in detail withreference to the accompanying drawings so that they can be easilypracticed by those skilled in the art to which the present inventionpertains. Here, the accompanying drawings may be shown in a somewhatexaggerated manner for the description thereof, and may be merelyprovided as a reference without limiting the scope of the presentinvention.

FIG. 5 is a schematic view showing a method for manufacturing acutting/polishing tool according to an exemplary embodiment of thepresent invention. FIG. 6 is an enlarged view of a claddinglayer-forming section of FIG. 5. FIG. 7 is a schematic view showing amethod for manufacturing a cutting/polishing tool according to anotherexemplary embodiment of the present invention. FIG. 8 is a schematicview showing a method for manufacturing a cutting/polishing tool havinga plane cutting/polishing body according to an exemplary embodiment ofthe present invention. FIG. 9 is a schematic view showing a method formanufacturing a cutting/polishing tool according to another exemplaryembodiment of the present invention. FIGS. 10(a) to 10(c) are schematicviews sequentially showing a method for manufacturing acutting/polishing tool including a plurality of accumulated claddinglayers according to an exemplary embodiment of the present invention.FIGS. 11(a) to 11(c) are partially cut-away perspective views showingvarious examples of a cutting/polishing tool having a wide areaaccording to an exemplary embodiment of the present invention. FIG. 12is a partially cut-away perspective view showing a cutting/polishingtool where a plurality of cladding layers having a wide area isaccumulated according to an exemplary embodiment of the presentinvention. FIGS. 13(a) and 13(b) are cross-sectional views showing acutting/polishing tool including a cutting/polishing body configured asa single cladding layer according to an exemplary embodiment of thepresent invention. FIG. 14 is a partially cut-away perspective viewshowing a cutting/polishing tool configured as a single cladding layerand having a wide area according to an exemplary embodiment of thepresent invention. FIGS. 15(a) to 15(d) are examples of acutting/polishing tool that is manufactured into various shapesaccording to an exemplary embodiment of the present invention.

First, referring to FIGS. 5 and 6, a method for manufacturing acutting/polishing tool according to an exemplary embodiment of thepresent invention will hereinafter be described.

The method for manufacturing the cutting/polishing tool according to thepresent exemplary embodiment of the present invention may relate to amethod for manufacturing a cutting/polishing tool 100 including at leastone cutting/polishing body 120, and include preparing a tool body andforming a cladding layer.

The preparing of the tool body may prepare a tool body 110 where acutting/polishing body 120 is formed, similar to a typicalcutting/polishing tool. As an example, as shown in FIG. 5, the tool body110 may be formed of a disk shaped metal body on which grooves 112partitioning parts where the cutting/polishing body 120 is formed areformed.

In addition, the forming of the cladding layer may include spraying, toan outer surface 111 of the tool body 110, cutting material particles(D) and a metal powder (M) having a specific gravity greater than aspecific gravity of the cutting material particles (D) while heating theouter surface 111 of the tool body 110 using a heating device 210installed in a lower side of the outer surface 111 of the tool body 110.Through the spraying, the metal powder (M) may be deposited on the outersurface 111 of the tool body 110 to form the cladding layer, and thecutting material particles (D) may be included within the claddinglayer. In this manner, the cladding layer where the cutting materialparticles (D) and metal powder (M) are deposited may configure thecutting/polishing body 120.

As described above, in a case of heating the outer surface 111 of thetool body 110 in a lower side direction of the outer surface 111 of thetool body 110, the cutting material particles (D) having a relativelysmaller specific gravity are floating upward above a molten pool in adirection opposite to a gravity direction (G) as shown in FIG. 6, andare distributed in a part closer to the tool body 110. Accordingly,since the cutting material particles (D) are not exposed to the outsidefrom a surface of the cutting/polishing body 120, it is possible to forman additional cladding layer, which will be described later.

Meanwhile, the cutting material particles (D) supplied from a cuttingmaterial particle-supplying part 221 and the metal powder (M) suppliedfrom a metal powder-supplying part 222 may be mixed in a materialspraying part 220, and then may be sprayed through a nozzle. In thisinstance, a spraying amount of each of the cutting material particles(D) and the metal powder (M) supplied to the material spraying part 220may be separately controlled in the cutting material particle-supplyingpart 221 and the metal powder-supplying part 222, respectively.

As the metal powder sprayed from the metal powder-supplying part 222, atypical metal powder may be used, as examples of the metal powder, onemetal or at least two metals selected from ferrous and non-ferrous metalgroups including Fe, Cu, Co, Ni, Cr, Ti, W, WC, Sn, CuSn, Ag, and P maybe given. As another example of the metal powder, a pre-alloyed powderincluding one metal or at least two metals selected from the abovedescribed metal groups may be given. Also, the cutting materialparticles supplied from the cutting material-supplying part 221 may beselected from a group consisting of diamond particles, carbide, boricacids, nitrides, and hard metal and ceramic pieces, and as an example,diamond particles having a most excellent hardness may be used.

Also, as the heating device 210, various types of the heating device maybe used, however, a laser device having high energy intensity may bepreferably used to enhance efficiency of the cladding. Meanwhile, in acase where the cutting material particles (D) include diamond particles,a laser device that emits a laser having a wavelength capable ofpenetrating the diamond particles may be used as the heating device 210,so that the diamond particles are not melted. As the laser device, anyone of a CO₂ laser device, an Nd-YAG laser device, a fiber laser device,a diode laser device, and a disk laser device may be used.

In addition, since the diamond particles are susceptible to heat, anoutput of the heating device 210 may be desirably adjusted so that atemperature of the molten pool in which the metal powder (M) is melteddoes not exceed a preset temperature. For this, a contactlesstemperature sensor (not shown) measuring the temperature of the moltenpool may be provided, and a control part (not shown) may reduce theoutput of the heating device 210 when the temperature of the molten poolsensed in the temperature sensor exceeds the preset temperature, andotherwise, may increase the output of the heating device 210 so that thecladding may be effectively generated.

Referring to FIGS. 5 and 6, the outer surface 111 of the tool body 110may be divided into a plurality of cladding layer-forming sections (S)corresponding to a part where the deposition of the metal powder (M) isprocessed by the heating device 210 in accordance with a relativetransfer of the tool body 110 and the heating device 210. Specifically,the cladding layer-forming section (S) may be a portion of the outersurface 111 of the tool body 110 corresponding to a portion in which themolten pool is generated by the heating of the heating device 210.

In this instance, so that the cutting material particles (D) areuniformly distributed on the cutting/polishing body 120, an angle (θ,theta) between a vertical line (VL) perpendicular to the claddinglayer-forming section (S) and the gravity direction (G) may desirablyhave a range of −10 degrees to 40 degrees in a state where the heatingis performed from a lower side of the tool body 110 by the heatingdevice 210.

Referring to FIG. 5, the angle (θ) between the vertical line (VL)perpendicular to the cladding layer-forming section (S) and the gravitydirection (G) is a zero-degree, and a positive value and a negativevalue of the angle are determined based on an advancing direction (X) ofthe tool. For example, as for the angle (θ), the advancing direction (X)of the tool may have the positive value, and a direction opposite to theadvancing direction of the tool may have the negative value, withrespect to the cladding layer-forming section (S). Specifically, in FIG.5, an angle (θ) between a vertical line (VL1) perpendicular to acladding layer-forming section (S1) and the gravity direction (G) has apositive value, and an angle (−θ) between a vertical line (VL2)perpendicular to a cladding layer-forming section (S2) and the gravitydirection (G) has a negative value.

In this manner, when the angle (θ) between the vertical line (VL)perpendicular to the cladding layer-forming section (S) and the gravitydirection (G) is in a range of −10 degrees to 40 degrees, the cuttingmaterial particles (D) may be floating upward above the molten pool, andmay be rarely located in an outer surface side of the cutting/polishingbody 120 as shown in FIG. 6, and thereby it is possible to form anadditional cladding layer on the previously formed cladding layerwithout causing oxidation or performance degradation of the cuttingmaterial particles (D). In this instance, when the angle (θ) is lessthan the −10 degrees or greater than the 40 degrees, the cuttingmaterial particles (D) may be moved to the outer surface side of thecutting/polishing body 120, and thereby it is difficult to form theadditional cladding layer, or the performance of the cutting materialparticles (D) may be degraded.

In FIG. 7, a case in which the angle (θ) between the vertical line (VL)perpendicular to the cladding layer-forming section (S) and the gravitydirection (G) is about 30 degrees in a state where the heating isperformed from the lower side of the tool body 110 by the heating device210 is shown. In this manner, when the angle (θ) between the verticalline (VL) perpendicular to the cladding layer-forming section (S) andthe gravity direction (G) is about 30 degrees, for example, when theangle is in a range of 25 degrees to 35 degrees, since the molten poolgenerated by the relative transfer of the tool body 110 and the heatingdevice 210 is widely generated in a horizontal direction perpendicularto the gravity direction, the cutting material particles (D) may bedistributed throughout the entire thickness of the cutting/polishingbody 120 although the cutting material particles (D) are floating withinthe molten pool.

However, an angle (θ) at which the cutting material particles (D) aredistributed throughout the entire thickness of the cutting/polishingbody 120 may be changed depending on a transfer speed of the tool body110 or a cooling rate of the molten pool, however, may be determined inan angle range closer to the 30 degrees.

Here, when the angle (θ) between the vertical line (VL) perpendicular tothe cladding layer-forming section (S) and the gravity direction (G) isin a range of −10 degrees to 40 degrees, the cutting material particles(D) may be rarely located in the outer surface side of thecutting/polishing body 120, and therefore it is possible to form anadditional cladding layer on the previously formed cladding layerwithout causing oxidation or performance degradation of the cuttingmaterial particles (D). When the angle (θ) is about 30 degrees (forexample, a range of 25 degrees to 35 degrees), the cutting materialparticles (D) may be uniformly distributed throughout the entirethickness of the cutting/polishing body 120, and thereby the performanceof the cutting/polishing body 120 may be improved.

In FIG. 8, unlike FIG. 5 and FIG. 7, so that the cutting/polishing body120 is formed on a plane of the tool body 110, a case in which atranslational movement is performed with respect to the tool body 110may be shown. In this case of FIG. 8, since the heating is performedfrom the lower side of the tool body 110 by the heating device 210, andthe angle (θ) between the vertical line (VL) perpendicular to thecladding layer-forming section (S) and the gravity direction (G) is inthe range of −10 degrees to 40 degrees, the cutting material particles(D) may be rarely located in the outer surface side of thecutting/polishing body 120, and thereby it is possible to form theadditional cladding layer on the previously formed cladding layerwithout causing an oxidation or performance degradation of the cuttingmaterial particles (D). Meanwhile, as shown in FIG. 5 and FIG. 8, thecladding layer-forming section (S) in which the molten pool is generatedmay be moved in the direction (X) perpendicular to the gravity direction(G), and the angle (θ) between the vertical line (VL) perpendicular tothe cladding layer-forming section (S) and the gravity direction (G) maybe maintained in the range of −10 degrees to 40 degrees while thecutting material particles (D) are fixedly located in a state of beingfloating within the cladding layer-forming section (S) to be cooled(solidified). Specifically, since a period of time during which themolten pool is generated by the heating of the heating device 210 issignificantly short, when the cladding layer-forming section (S) ismoved in the direction (X) perpendicular to the gravity direction (G)due to the movement of the tool body 110, the cutting material particles(D) may be fixedly located within the cooled metal powder (M), andrarely located on the outer surface side of the cutting/polishing body120, and thereby it is possible to form an additional cladding layer onthe previously formed cladding layer without causing an oxidation orperformance degradation of the cutting material particles (D).

In addition, as shown in FIG. 9, the forming of the cladding layer maybe configured such that the cladding layer-forming section (S) is heatedwhile an angle (θ1) smaller than 40 degrees with respect to the gravitydirection (G) is realized in a heating direction (TL) of the heatingdevice 210, and even in this case, effects similar to those in FIG. 5,FIG. 7, and FIG. 8 may be obtained.

Meanwhile, referring to FIG. 10, the method for manufacturing thecutting/polishing tool according to an exemplary embodiment of thepresent invention may further include accumulating new cladding layers141, 142, and 143 including the cutting material particles (D) byspraying, to a surface 131 of the previously formed cladding layer 130,the cutting material particles (D) and the metal powder (M) whileheating the surface 131 of the previously formed cladding layer 130using the heating device 210 so that the metal powder (M) is depositedon the surface 131 of the previously formed cladding layer 130. In thiscase, the accumulated cladding layers may configure thecutting/polishing body. In this instance, as for each of the forming ofthe cladding layer, in order to prevent oxidation, performancedegradation and floating (separation from the previously formed claddinglayer) of the cutting material particles (D) from occurring at the timeof the forming of the accumulated cladding layers, an amount of each ofthe cutting material particles and the metal powder may be desirablydetermined such that the cutting material particles (D) are not exposedto the outside after the deposition of the metal powder (M) iscompleted. Specifically, after the cladding layer 130 including thecutting material particles (D) is formed while the metal powder (M) isdeposited on the outer surface 111 of the tool body 110 (see FIG.10(a)), the additional cladding layer 141 formed such that the metalpowder (M) is deposited on the surface 131 of the previously formedcladding layer 130 may be formed (see FIG. 10(b)). This process offorming the additional cladding layer may be repeatedly performed toform several cladding layers 142 and 143 as shown in FIG. 10(C). In thismanner, the cladding layer 130 formed on the outer surface 111 of thetool body 110 and the accumulated cladding layer 140 formed on the outersurface of the previously formed cladding layer may be combined toconfigure the cutting/polishing body 120, and thereby a thickness(height) of the cutting/polishing body may be increased.

When repeatedly forming the cladding layer 130, the metal powder (M)adjacent to the surface 131 may be melted due to a newly performeddeposition to generate a molten pool on the surface 131 of thepreviously formed cladding layer 130, and thereby newly supplied cuttingmaterial particles (D) may float towards a side of the tool body 110within the molten pool in the new cladding layer 141. Accordingly, byadjusting a supplied amount of the metal powder (M) and a quantity ofheat applied to the molten pool, it is possible to enable the cuttingmaterial particles (D) to have a uniform distribution throughout theentire thickness of the cutting/polishing body 120.

In addition, in order to expose the cutting material particles (D) inthe cladding layer 143 located on the surface of the cutting/polishingbody 120, dressing of the cutting/polishing body 120 may be furtherincluded.

Next, referring to FIG. 11(a), in order to form the cladding layer 130having a wide area (range), the cladding layer 130 may be formed suchthat a plurality of segment layers S1, S2, S3, S4, S5, and S6 includingthe cutting material particles (D) is combined while the metal power (M)is deposited. In this case, the cladding layer 130 may be formed suchthat the plurality of segment layers S1, S2, S3, S4, S5, and S6, whichare classified depending on whether to include the cutting materialparticles (D) and a content (amount) of the cutting material particles(D), are combined. As an example, as shown in FIG. 11(b), the claddinglayer 130 may include first segment layers S2, S4, and S6 including thecutting material particles (D) while the metal powder (M) is deposited,and second segment layers S1, S3, and S5 not including the cuttingmaterial particles (D) while the metal powder (M) is deposited. Also, asshown in FIG. 11(c), the cladding layer 130 may include first segmentlayers S2, S3, S5, and S6 including the cutting material particles (D)while the metal powder (M) is deposited, and second segment layers S1,and S4 not including the cutting material particles (D) while the metalpowder (M) is deposited, and the first segment layers S2, S3, S5, and S6may be further classified depending on the content of the cuttingmaterial particles (D). In this manner, a single cladding layer 130 maybe embodied in various types depending on whether to include the cuttingmaterial particles (D) and the content of the cutting material particles(D), and thereby it is possible to manufacture the cutting/polishingtool having various structures and functions.

In addition, as shown in FIG. 12, the single cladding layer 130including the plurality of segment layers S1, S2, S3, S4, S5, and S6 maybe formed, and the accumulated cladding layer 141 including theplurality of segment layers S1, S2, S3, S4, S5, and S6 may be repeatedlyformed on the previously formed cladding layer 130, and thereby it ispossible to manufacture the cutting/polishing body having a wide areaand a great thickness.

Next, referring to FIG. 13, the forming of the cladding layer may beperformed such that a spraying amount of each of the cutting materialparticles (D) and the metal powder (M) is determined to enable a portionof the cutting material particles (D) to be exposed when the depositionof the metal powder (M) is completed, and thereby the cladding layerformed as a single layer may configure the cutting/polishing body 120.In this case, as shown in FIGS. 13(a) and 13(b), so that a height of thecladding layer 130 or a content of the cutting material particles (D) isadjusted, a spraying amount of at least one of the cutting materialparticles (D) and the metal powder (M) may be adjusted.

Also, as shown in FIG. 14, the cladding layer formed as the single layermay be formed such that a plurality of segment layers S1, S2, and S3 arecombined on the cutting/polishing body 120, and as described in FIGS.11(a) to 11(c), it is possible to have various structures depending onthe inclusion of the cutting material particles (D) and the content ofthe cutting material particles (D).

Also, in order to form the cutting/polishing body 120, a relativemovement between the heating device 210 and the tool body 110 may berequired, and for this, a translational movement may be performed withrespect to the tool body 110 (see FIG. 8), a rotary movement may beperformed with respect to the tool body 110 (see FIGS. 5, 7, and 9), ora translational/rotary movement may be performed with respect to thetool body 110.

In this manner, in the cladding layer formed as the single layer, thecutting/polishing body 120 having various shapes may be formed on thetool body 110 having various types, as shown in FIGS. 15(a) to 15(d).Accordingly, it is possible to manufacture the cutting/polishing toolhaving various functions and performances.

Meanwhile, the method for manufacturing the cutting/polishing toolaccording to an exemplary embodiment of the present invention may beapplied to repair the tool including a damaged cutting/polishing body,and in this case, the cladding layer may be formed with respect to thedamaged cutting/polishing body.

Hereinafter, a cutting/polishing tool according to another exemplaryembodiment of the present invention will be described.

Referring to FIGS. 5 and 10, the cutting/polishing tool may include thetool body 110 according to the present invention, and at least onecutting/polishing body 120 including a cladding layer having the cuttingmaterial particles (D) while the cladding layer is formed such that themetal powder (m) is deposited on the outer surface 111 of the tool body110. Here, the cutting material particles (D) of the cladding layer 130that are directly formed on the outer surface 111 of the tool body 110may be more densely located in a part closer to the tool body 110 ratherthan a part further away from the tool body 110, as shown in FIG. 10(a).

In this instance, as shown in FIGS. 10(b) and 10(c), thecutting/polishing body 110 may be formed such that a plurality ofcladding layers 130 and 140 are accumulated, and may include the cuttingmaterial particles (D) having a uniform distribution throughout athickness of the cutting/polishing body 120.

Also, as shown in FIGS. 11(a) to 11(c), the cladding layers 130 and 140may be formed such that a plurality of segment layers S1, S2, S3, S4,S5, and S6, formed such that the metal powder (M) is deposited, arecombined. In this case, the cladding layer 130 may be formed such thatthe plurality of segment layers S1, S2, S3, S4, S5, and S6, classifieddepending on whether to include the cutting material particles (D) and acontent of the cutting material particles (D), are combined. As anexample, as shown in FIG. 11(b), the cladding layer 130 may includefirst segment layers S2, S4, and S6 including the cutting materialparticles (D) while the metal powder (M) is deposited, and secondsegment layers S1, S3, and S5 not including the cutting materialparticles (D) while the metal powder (M) is deposited. Also, as shown inFIG. 11(c), the cladding layer 130 may include first segment layers S2,S3, S5, and S6 including the cutting material particles (D) while themetal powder (M) is deposited, and second segment layers 51 and S4 notincluding the cutting material particles (D) while the metal powder (M)is deposited, and the first segment layers S2, S3, S5, and S6 may befurther classified depending on an amount of the cutting materialparticles (D).

Also, as shown in FIG. 14, in a case where a single cladding layerconfigures the cutting/polishing body 120, the cladding layer may have aconfiguration where a portion of the cutting material particles (D) isexposed to the outside without being covered with the metal powder (M),and thereby it is possible to manufacture various types of thecutting/polishing tool 100 as shown FIGS. 15(a) to 15(d).

The present invention is not limited to the above-mentioned embodimentsand the accompanying drawings. It is to be noted that componentsaccording to the present invention can be substituted, modified, andchanged without departing from the technical spirit of the presentinvention.

1-23. (canceled)
 24. A cutting/polishing tool, comprising: a tool body;and at least one cutting/polishing body including a cladding layerhaving cutting material particles while the cladding layer is formedsuch that a metal powder is deposited on an outer surface of the toolbody, wherein the cutting material particles of the cladding layer aremore densely located in a part closer to the tool body rather than apart further away from the tool body, the cladding layer being directlyformed on the outer surface of the tool body.
 25. The cutting/polishingtool of claim 24, wherein the cutting/polishing body is formed such thata plurality of cladding layers are accumulated, and thecutting/polishing body includes the cutting material particles having auniform distribution throughout a thickness of the cutting/polishingbody. 26-29. (canceled)